Surface mountable wireless power transmitter for transmission at extended range

ABSTRACT

A surface mountable housing for a power transmitter for wireless power transfer includes a connector system configured for use to mount, at least, a transmitter antenna to an underside of a structural surface, such that the transmitter antenna is configured to couple with a receiver antenna of a power receiver when the receiver antenna is proximate to a top side of the structural surface. The surface mountable housing further includes a heat sink, the heat sink configured to rest, at least in part, below the transmitter antenna, when the power transmitter is connected to the structural surface, and configured to direct heat generated by the power transmitter away from the structural surface, and an antenna housing, the antenna housing substantially surrounding a side wall of the transmitter antenna, the antenna housing connected to the heat sink and positioned between the heat sink and the structural surface.

TECHNICAL FIELD

The present disclosure generally relates to systems and methods forwireless transfer of electrical power and, more particularly, to surfacemountable wireless power transmitters for transmitting power at extendedseparation distances.

BACKGROUND

Wireless power transfer systems are used in a variety of applicationsfor the wireless transfer of electrical energy, electrical powersignals, electromagnetic energy, electrical data signals, among otherknown wirelessly transmittable signals. Such systems often use inductivewireless power transfer, which occurs when magnetic fields created by atransmitting element induce an electric field, and hence, an electriccurrent, in a receiving element. These transmission and receiverelements will often take the form of coiled wires and/or antennas.

Because some wireless power transfer systems are operable and/or mostefficient in the near-field, some transmitters may be limited to havingoperability only at restrictively small gaps between the transmittercoil and the receiver coil. To that end, typical wireless powertransmitters under the Wireless Power Consortium's Qi™ standard may belimited to operability at a maximum coil-to-coil separation gap (whichmay be referred to herein as a “separation gap” or “gap”) of about 3millimeters (mm) to about 5 mm. The separation gap is sometimes known asthe Z-height or Z-distance and is generally measured as the distancebetween the transmitter coil and receiver coil.

As the adoption of wireless power grows, commercial applications arerequiring a power transmitter capable of transferring power to a powerreceiver with a gap greater than 3-5 mm. By way of example, cabinetsand/or counter tops may be more than 3-5 mm thick and as a result,prevent wireless charging through such furniture. Accordingly, if awireless power transmitter is only capable of transmitting through 3-5mm of materials, such a charger may need to, expensively, be built intosuch infrastructure, like cabinets, countertops, and/or tables. Suchneed for built in chargers limits modularity, in terms of placement ofthe power transmitter relative to the infrastructure.

SUMMARY

Accordingly, new wireless power transmitters that are capable ofattachment underneath a surface and can properly couple with a powerreceiver atop said surface are desired. To that end, wireless powertransmitters and/or associated base stations are desired that arecapable of delivering wireless power signals to a power receiver at aseparation gap larger than the about 3 mm to about 5 mm separation gapsof legacy transmitters, so that such wireless power transmitters can beattached to the bottom of a surface and transmit to a receiver atop saidsurface.

In an embodiment, the overall structure of the transmitter is configuredin a way that allows the transmitter to transfer power at an operatingfrequency of about 87 kilohertz (kHz) to about 205 kHz and achieve thesame and/or enhanced relative characteristics (e.g., rate of powertransfer, speed of power transfer, power level, power level management,among other things) of power transfer as legacy transmitters thatoperated in that frequency range. As a result, the separation gap may beincreased from about 3-5 mm to around 15 mm or greater using the overallstructure of the transmitter. In an embodiment, a transmitter may beconfigured with a ferrite core that substantially surrounds thetransmitter antenna on three sides. The only place that the ferrite coredoes not surround the transmitter antenna is on the top (e.g., in thedirection of power transfer) and where the power lines connect to thetransmitter antenna. This overall structure of the transmitter allowsfor the combination of power transfer characteristics, power levelcharacteristics, self-resonant frequency restraints, designrequirements, adherence to standards bodies' required characteristics,bill of materials (BOM) and/or form factor constraints, among otherthings, that allow for power transfer over larger separation gaps.

Further, as increasing the separation gap may be associated with a risein power levels, proper thermal mitigation should be utilized in new,higher separation gap wireless power transmitters. The systems andapparatus described herein allow for such thermal mitigation, so thatthe large separation gap is achieved without doing damage to one or moreof the power transmitter, the device to be powered and/or power receiverassociated with said device, the surface to which the power transmitteris mounted, or combinations thereof.

Additionally, the utilization of the power transmitters and/ortransmitter antennas, disclosed herein, as part of a surface mountablepower transmitter allow for greater modularity in transmitter placement,relative to the surface upon which the power transmitter is mounted.Further, in some examples, the extended separation distance achieved bythe power transmitters, disclosed herein, may allow for usage of surfacemountable power transmitters on thicker surface thicknesses and/orthicker materials for the surfaces, when compared with legacysurface-associated power transmitters.

Transmission of one or more of electrical energy, electrical power,electromagnetic energy or electronic data signals from one of suchcoiled antennas to another, generally, operates at an operatingfrequency and/or an operating frequency range. The operating frequencymay be selected for a variety of reasons, such as, but not limited to,power transfer characteristics, power level characteristics,self-resonant frequency restraints, design requirements, adherence tostandards bodies' required characteristics, bill of materials (BOM)and/or form factor constraints, among other things. It is to be notedthat, “self-resonating frequency,” as known to those having skill in theart, generally refers to the resonant frequency of an inductor due tothe parasitic characteristics of the component.

In accordance with one aspect of the disclosure, a power transmitter forwireless power transfer at an operating frequency selected from a rangeof about 87 kilohertz (kHz) to about 205 kHz is disclosed. The powertransmitter includes a control and communications unit, an invertercircuit configured to receive input power and convert the input power toa power signal, and a transmitter antenna. The transmitter antennaincludes a coil configured to transmit the power signal to a powerreceiver, the coil formed of wound Litz wire and including at least onelayer, the coil defining, at least, a top face, and a shieldingcomprising a ferrite core and defining a cavity, the cavity configuredsuch that the ferrite core substantially surrounds all but the top faceof the coil. The power transmitter further includes a surface mountablehousing, the surface mountable housing substantially connected to, atleast, the transmitter antenna and the surface mountable housingincluding a connector system configured for use to mount, at least, thetransmitter antenna to an underside of a structural surface such thatthe transmitter antenna is configured to couple with a receiver antennaof the power receiver when the receiver antenna is proximate to a topside of the structural surface.

In a refinement, at least part of the surface mountable housing furtherincludes a heat sink, the heat sink configured to rest, at least inpart, below the transmitter antenna, when the power transmitter isconnected to the structural surface, and configured to direct heatgenerated by the power transmitter away from the structural surface

In a further refinement, the power transmitter further includes atransmitter electronics circuit board, the transmitter electronicscircuit board including components of one or more of the control andcommunications circuit, the inverter circuit, or combinations thereof,and the heat sink is configured to dissipate heat, generated by one ormore of the electronics circuit board or components located on theelectronics circuit board, away from the structural surface.

In yet a further refinement, the power transmitter further includes athermal interface material, the thermal interface material disposedbetween the electronics circuit board and the heat sink and configuredto direct heat from the electronics circuit board to the heat sink.

In yet a further refinement, the thermal interface material includes oneor more of a thermal paste, a thermal adhesive, a thermal gap filter, athermally conductive pad, a thermal tape, a phase-change material, ametal thermal interface, or combinations thereof.

In another further refinement, the surface mountable housing furtherincludes an antenna housing, the antenna housing substantiallysurrounding a side wall of the transmitter antenna and the antennahousing is connected to the heat sink and positioned between the heatsink and the structural surface.

In another further refinement, the heat sink defines one or more cutouts, each of the one or more cut outs configured to increase externalsurface area of the heat sink.

In another further refinement, the heat sink is formed, at least inpart, from aluminum.

In a refinement, thickness between the underside of the structuralsurface and the top side of the structural surface is in a range ofabout 5 millimeters (mm) to about 15 mm, and the surface mountablehousing is configured to mount directly to the underside of thestructural surface via the connection system.

In a refinement, a surface thickness is defined as a thickness betweenthe underside of the structural surface and the top side of thestructural surface, the structural member defines a hole, the holedefining a hole ceiling and a hole opening, a hole thickness is definedas a thickness between the hole ceiling and the hole opening, the holethickness is less than the surface thickness, and the surface mountablehousing is configured to mount to the hole ceiling of the hole of thestructural surface.

In a further refinement, the surface thickness is in a range of about 20mm to about 60 mm and the hole thickness is in a range of about 5 mm toabout 50 mm.

In accordance with another aspect of the disclosure, a surface mountablepower transmitter for wireless power transfer at an operating frequencyselected from a range of about 87 kilohertz (kHz) to about 205 kHz, thesurface mountable power transmitter configured to be mounted on anunderside of a structural surface, is disclosed. The surface mountablepower transmitter includes a control and communications unit, aninverter circuit configured to receive input power and convert the inputpower to a power signal, and a transmitter antenna. The transmitterantenna includes a coil configured to transmit the power signal to apower receiver, the coil formed of wound Litz wire and including atleast one layer, the coil defining, at least, a top face, and ashielding comprising a ferrite core and defining a cavity, the cavityconfigured such that the ferrite core substantially surrounds all butthe top face of the coil. The power transmitter further includes asurface mountable housing, the surface mountable housing substantiallyconnected to, at least, the transmitter antenna and the surfacemountable housing including a connector system configured for use tomount, at least, the transmitter antenna to an underside of a structuralsurface such that the transmitter antenna is configured to couple with areceiver antenna of the power receiver when the receiver antenna isproximate to a top side of the structural surface.

In a refinement, the shielding is an E-Core type shielding and thecavity is configured in an E-shape configuration.

In a refinement, the at least one layer comprises a first layer and asecond layer.

In a further refinement, the Litz wire is a bifilar Litz wire.

In yet a further refinement, the first layer includes a first number ofturns in a range of about 4 turns to about 5 turns, and wherein thesecond layer includes a second number of turns in a range of about 4turns to about 5 turns.

In a refinement, a shielding outer edge of the shielding extends about4.5 millimeters (mm) to about 6.5 mm outward from a coil outer edge ofthe coil.

In a refinement, the coil has an outer diameter length in a range ofabout 40 mm to about 50 mm.

In a refinement, the coil has an inner diameter length in a range ofabout 15 mm to about 25 mm.

In accordance with yet another aspect of the disclosure, a surfacemountable housing for a power transmitter for wireless power transfer atan operating frequency selected from a range of a about 87 kilohertz(kHz) to about 205 kHz, the power transmitter including, at least, atransmitter antenna, is disclosed. The surface mountable housingincludes a connector system configured for use to mount, at least, thetransmitter antenna to an underside of a structural surface, such thatthe transmitter antenna is configured to couple with a receiver antennaof a power receiver when the receiver antenna is proximate to a top sideof the structural surface. The surface mountable housing furtherincludes a heat sink, the heat sink configured to rest, at least inpart, below the transmitter antenna, when the power transmitter isconnected to the structural surface, and configured to direct heatgenerated by the power transmitter away from the structural surface, andan antenna housing, the antenna housing substantially surrounding a sidewall of the transmitter antenna, the antenna housing connected to theheat sink and positioned between the heat sink and the structuralsurface.

These and other aspects and features of the present disclosure will bebetter understood when read in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary block diagram of an embodiment of a wirelesspower transfer system, in accordance with an embodiment of the presentdisclosure.

FIG. 2 is an exemplary block diagram for a power transmitter, which maybe used in conjunction with the wireless power transfer system of FIG.1, in accordance with FIG. 1 and an embodiment of the presentdisclosure.

FIG. 3 is an exemplary block diagram for components of a control andcommunications system of the power transmitter of FIG. 2, in accordancewith FIGS. 1-2 and an embodiment of the present disclosure.

FIG. 4 is an exemplary block diagram for components of a sensing systemof the control and communications system of FIG. 3, in accordance withFIGS. 1-3 and an embodiment of the present disclosure.

FIG. 5 is an exemplary block diagram for components of a powerconditioning system of the power transmitter of FIGS. 1-2, in accordancewith FIGS. 1-2 and an embodiment of the present disclosure.

FIG. 6 is an exemplary electrical schematic diagram of components of thepower transmitter of FIGS. 1-5, in accordance with FIGS. 1-5 and thepresent disclosure.

FIG. 7 is a perspective view of a shape of a transmitter coil of thepower transmitter of FIGS. 1-6, in accordance with FIGS. 1-6 and anembodiment of the present disclosure.

FIG. 8 is a cross-section of components of a base station, with whichthe power transmitter 20 is associated, in accordance with FIGS. 1-7 andthe present disclosure.

FIG. 9 is a perspective view of a shielding associated with thetransmitter coil of FIGS. 1-8, in accordance with FIGS. 1-8 and anembodiment of the present disclosure.

FIG. 10A is a perspective view of the transmitter coil of FIGS. 1-8 andthe shielding of FIGS. 8 and 9, in accordance with FIGS. 1-9 and thepresent disclosure.

FIG. 10B is an exploded perspective view of the transmitter coil ofFIGS. 1-8 and the shielding of FIGS. 8 and 9, in accordance with FIGS.1-9 and the present disclosure.

FIG. 11A is a perspective top view of a surface mountable powertransmitter utilizing one or more of the power transmitters, thetransmitter antennas, or combinations thereof, described in FIGS. 1-10,in accordance with FIGS. 1-10 and the present disclosure.

FIG. 11B is a perspective bottom view of the surface mountable powertransmitter of FIG. 11A, in accordance with FIGS. 1-11A and the presentdisclosure.

FIG. 11C is an exploded perspective view of the surface mountable powertransmitter of FIGS. 11A-B, in accordance with FIGS. 1-11B and thepresent disclosure.

FIG. 11D is a side, cross-sectional view of the surface mountable powertransmitter of FIGS. 11-C, in accordance with FIGS. 1-11C and thepresent disclosure.

FIG. 11E is a bottom view of the surface mountable power transmitter ofFIGS. 11A-D, in accordance with FIGS. 1-11D and the present disclosure.

FIG. 12 is cross sectional side view of the surface mountable powertransmitter of FIG. 11, illustrating an exemplary usage of the surfacemountable power transmitter of FIG. 11, with respect to a surface, inaccordance with FIGS. 1-11 and the present disclosure.

FIG. 13A is a cross sectional side view of the surface mountable powertransmitter of FIG. 11, illustrating another exemplary usage of thesurface mountable power transmitter of FIG. 11, with respect to asurface, in accordance with FIGS. 1-11 and the present disclosure.

FIG. 13B is a bottom perspective view of the illustrated exemplary usageof the surface mountable power transmitter of FIG. 13A, in accordancewith FIGS. 1-11, 13A and the present disclosure.

FIG. 14 is a cross sectional side view of the surface mountable powertransmitter of FIG. 11, illustrating another exemplary usage of thesurface mountable power transmitter of FIG. 11, with respect to asurface, in accordance with FIGS. 1-11 and the present disclosure.

FIG. 15 is a readout of an actual simulation of magnetic fieldsgenerated by the coils and/or transmitters illustrated in FIGS. 1-14 anddisclosed herein.

FIG. 16 is a flow chart for an exemplary method for designing a powertransmitter, in accordance with FIGS. 1-15 and the present disclosure.

FIG. 17 is a flow chart for an exemplary method for manufacturing apower transmitter, in accordance with FIGS. 1-16 and the presentdisclosure.

While the following detailed description will be given with respect tocertain illustrative embodiments, it should be understood that thedrawings are not necessarily to scale and the disclosed embodiments aresometimes illustrated diagrammatically and in partial views. Inaddition, in certain instances, details which are not necessary for anunderstanding of the disclosed subject matter or which render otherdetails too difficult to perceive may have been omitted. It shouldtherefore be understood that this disclosure is not limited to theparticular embodiments disclosed and illustrated herein, but rather to afair reading of the entire disclosure and claims, as well as anyequivalents thereto. Additional, different, or fewer components andmethods may be included in the systems and methods.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth byway of examples in order to provide a thorough understanding of therelevant teachings. However, it should be apparent to those skilled inthe art that the present teachings may be practiced without suchdetails. In other instances, well known methods, procedures, components,and/or circuitry have been described at a relatively high-level, withoutdetail, in order to avoid unnecessarily obscuring aspects of the presentteachings.

Referring now to the drawings and with specific reference to FIG. 1, awireless power transfer system 10 is illustrated. The wireless powertransfer system 10 provides for the wireless transmission of electricalsignals, such as, but not limited to, electrical energy, electricalpower signals, and electromagnetic energy. Additionally, the wirelesspower transfer system 10 may provide for wireless transmission ofelectronically transmittable data (“electronic data”) independent ofand/or associated with the aforementioned electrical signals.Specifically, the wireless power transfer system 10 provides for thewireless transmission of electrical signals via near field magneticcoupling. As shown in the embodiment of FIG. 1, the wireless powertransfer system 10 includes a power transmitter 20 and a power receiver30. The power receiver 30 is configured to receive electrical energy,electrical power, electromagnetic energy, and/or electronic data from,at least, the power transmitter 20.

As illustrated, the power transmitter 20 and power receiver 30 may beconfigured to transmit electrical energy, via transmitter antenna 21 andreceiver antenna 31, electrical power, electromagnetic energy, and/orelectronically transmittable data across, at least, a separationdistance or gap 17. A separation distance or gap, such as the gap 17, inthe context of a wireless power transfer system, such as the system 10,does not include a physical connection, such as a wired connection.There may be intermediary objects located in a separation distance orgap, such as the gap 17, such as, but not limited to, air, a countertop, a casing for an electronic device, a grip device for a mobiledevice, a plastic filament, an insulator, a mechanical wall, among otherthings; however, there is no physical, electrical connection at such aseparation distance or gap.

The combination of the power transmitter 20 and the power receiver 30create an electrical connection without the need for a physicalconnection. “Electrical connection,” as defined herein, refers to anyfacilitation of a transfer of an electrical current, voltage, and/orpower from a first location, device, component, and/or source to asecond location, device, component, and/or destination. An “electricalconnection” may be a physical connection, such as, but not limited to, awire, a trace, a via, among other physical electrical connections,connecting a first location, device, component, and/or source to asecond location, device, component, and/or destination. Additionally oralternatively, an “electrical connection” may be a wireless electricalconnection, such as, but not limited to, magnetic, electromagnetic,resonant, and/or inductive field, among other wireless electricalconnections, connecting a first location, device, component, and/orsource to a second location, device, component, and/or destination.

Alternatively, the gap 17 may be referenced as a “Z-Distance,” because,if one considers an antenna 21, 31 to be disposed substantially along acommon X-Y plane, then the distance separating the antennas 21, 31 isthe gap in a “Z” or “depth” direction. However, flexible and/ornon-planar coils are certainly contemplated by embodiments of thepresent disclosure and, thus, it is contemplated that the gap 17 may notbe uniform, across an envelope of connection distances between theantennas 21, 31. It is contemplated that various tunings,configurations, and/or other parameters may alter the possible maximumdistance of the gap 17, such that electrical transmission from the powertransmitter 20 to the power receiver 30 remains possible.

The wireless power transfer system 10 operates when the powertransmitter 20 and the power receiver 30 are coupled. As defined herein,the terms “couples,” “coupled,” and “coupling” generally refers tomagnetic field coupling, which occurs when the energy of a transmitterand/or any components thereof and the energy of a receiver and/or anycomponents thereof are coupled to each other through a magnetic field.Coupling of the power transmitter 20 and the power receiver 30, in thesystem 10, may be represented by a resonant coupling coefficient of thesystem 10 and, for the purposes of wireless power transfer, the couplingcoefficient for the system 10 may be in the range of about 0.01 and 0.9.

The power transmitter 20 may be operatively associated with a basestation 11. The base station 11 may be a device, such as a charger, thatis able to provide near-field inductive power, via the power transmitter20, to a power receiver. In some examples, the base station 11 may beconfigured to provide such near-field inductive power as specified inthe Qi™ Wireless Power Transfer System, Power Class 0 Specification. Insome such examples, the base station 11 may carry a logo to visuallyindicate to a user that the base station 11 complies with the Qi™Wireless Power Transfer System, Power Class 0 Specification.

The power transmitter 20 may receive power from an input power source12. The base station 11 may be any electrically operated device, circuitboard, electronic assembly, dedicated charging device, or any othercontemplated electronic device. Example base stations 11, with which thepower transmitter 20 may be associated therewith, include, but are notlimited to including, a device that includes an integrated circuit,cases for wearable electronic devices, receptacles for electronicdevices, a portable computing device, clothing configured withelectronics, storage medium for electronic devices, charging apparatusfor one or multiple electronic devices, dedicated electrical chargingdevices, activity or sport related equipment, goods, and/or datacollection devices, among other contemplated electronic devices.

The input power source 12 may be or may include one or more electricalstorage devices, such as an electrochemical cell, a battery pack, and/ora capacitor, among other storage devices. Additionally or alternatively,the input power source 12 may be any electrical input source (e.g., anyalternating current (AC) or direct current (DC) delivery port) and mayinclude connection apparatus from said electrical input source to thewireless transmission system 20 (e.g., transformers, regulators,conductive conduits, traces, wires, or equipment, goods, computer,camera, mobile phone, and/or other electrical device connection portsand/or adaptors, such as but not limited to USB or lighting ports and/oradaptors, among other contemplated electrical components).

Electrical energy received by the power transmitter 20 is then used forat least two purposes: providing electrical power to internal componentsof the power transmitter 20 and providing electrical power to thetransmitter coil 21. The transmitter coil 21 is configured to wirelesslytransmit the electrical signals conditioned and modified for wirelesstransmission by the power transmitter 20 via near-field magneticcoupling (NFMC). Near-field magnetic coupling enables the transfer ofelectrical energy, electrical power, electromagnetic energy, and/orelectronically transmissible data wirelessly through magnetic inductionbetween the transmitter coil 21 and a receiving coil 31 of, orassociated with, the power receiver 30. Near-field magnetic coupling mayenable “inductive coupling,” which, as defined herein, is a wirelesspower transmission technique that utilizes an alternatingelectromagnetic field to transfer electrical energy between two or moreantennas/coils. Such inductive coupling is the near field wirelesstransmission of electrical energy between two magnetically coupled coilsthat are tuned to resonate at a similar frequency. Further, suchnear-field magnetic coupling may provide connection via “mutualinductance,” which, as defined herein is the production of anelectromotive force in a circuit by a change in current in at least onecircuit magnetically coupled to the first.

In one or more embodiments, the inductor coils of either the transmittercoil 21 or the receiver coil 31 are strategically positioned tofacilitate reception and/or transmission of wirelessly transferredelectrical energy, power, electromagnetic energy and/or data throughnear field magnetic induction. Antenna operating frequencies maycomprise all operating frequency ranges, examples of which may include,but are not limited to, about 87 kHz to about 205 kHz (Qi™ interfacestandard). The operating frequencies of the coils 21, 31 may beoperating frequencies designated by the International TelecommunicationsUnion (ITU) in the Industrial, Scientific, and Medical (ISM) frequencybands.

As known to those skilled in the art, a “resonant frequency” or“resonant frequency band” refers to a frequency or frequencies whereinamplitude response of the antenna is at a relative maximum, or,additionally or alternatively, the frequency or frequency band where thecapacitive reactance has a magnitude substantially similar to themagnitude of the inductive reactance. In one or more embodiments thetransmitting antenna resonant frequency band extends from about 87 kHzto about 205 kHz. In one or more embodiments the inductor coil of thereceiver coil 31 is configured to resonate at a receiving antennaresonant frequency or within a receiving antenna resonant frequencyband.

In some examples, the transmitting coil and the receiving coil of thepresent disclosure may be configured to transmit and/or receiveelectrical power at a baseline power profile having a magnitude up toabout 5 watts (W). In some other examples, the transmitting coil and thereceiving coil of the present disclosure may be configured to transmitand/or receive electrical power at an extended power profile, supportingtransfer of up to 15 W of power.

The power receiver 30 is configured to acquire near-field inductivepower from the power transmitter 20. In some examples, the powerreceiver 30 is a subsystem of an electronic device 14. The electronicdevice 14 may be any device that is able to consume near field inductivepower as specified in the Qi™ Wireless Power Transfer System, PowerClass 0 Specification. In some such examples, the electronic device 14may carry a logo to visually indicate to a user that the electronicdevice 14 complies with the Specification.

The electronic device 14 may be any device that requires electricalpower for any function and/or for power storage (e.g., via a batteryand/or capacitor). Additionally or alternatively, the electronic device14 may be any device capable of receipt of electronically transmissibledata. For example, the device may be, but is not limited to being, ahandheld computing device, a mobile device, a portable appliance, anintegrated circuit, an identifiable tag, a kitchen utility device, anautomotive device, an electronic tool, an electric vehicle, a gameconsole, a robotic device, a wearable electronic device (e.g., anelectronic watch, electronically modified glasses, altered-reality (AR)glasses, virtual reality (VR) glasses, among other things), a portablescanning device, a portable identifying device, a sporting good, anembedded sensor, an Internet of Things (IoT) sensor, IoT enabledclothing, IoT enabled recreational equipment, industrial equipment,medical equipment, a medical device, a tablet computing device, aportable control device, a remote controller for an electronic device, agaming controller, among other things.

For the purposes of illustrating the features and characteristics of thedisclosed embodiments, arrow-ended lines are utilized to illustratetransferrable and/or communicative signals and various patterns are usedto illustrate electrical signals that are intended for powertransmission and electrical signals that are intended for thetransmission of data and/or control instructions. Solid lines indicatesignal transmission of electrical energy, electrical power signals,and/or electromagnetic energy over a physical and/or wireless electricalconnection, in the form of power signals that are, ultimately, utilizedin wireless power transmission from the power transmitter 20 to thepower receiver 30. Further, dotted lines are utilized to illustrateelectronically transmittable data signals, which ultimately may bewirelessly transmitted from the power transmitter 20 to the powerreceiver 30.

Turning now to FIG. 2, the wireless power transfer system 10 isillustrated as a block diagram including example sub-systems of thepower transmitter 20. The wireless transmission system 20 may include,at least, a power conditioning system 40, a control and communicationssystem 26, a sensing system 50, and the transmission coil 21. A firstportion of the electrical energy input from the input power source 12 isconfigured to electrically power components of the wireless transmissionsystem 20 such as, but not limited to, the control and communicationssystem 26. A second portion of the electrical energy input from theinput power source 12 is conditioned and/or modified for wireless powertransmission, to the power receiver 30, via the transmission coil 21.Accordingly, the second portion of the input energy is modified and/orconditioned by the power conditioning system 40. While not illustrated,it is certainly contemplated that one or both of the first and secondportions of the input electrical energy may be modified, conditioned,altered, and/or otherwise changed prior to receipt by the powerconditioning system 40 and/or transmission control system 26, by furthercontemplated subsystems (e.g., a voltage regulator, a current regulator,switching systems, fault systems, safety regulators, among otherthings).

The control and communications system 26, generally, comprises digitallogic portions of the power transmitter 20. The control andcommunications system 26 receives and decodes messages from the powerreceiver 30, executes the relevant power control algorithms andprotocols, and drives the frequency of the AC waveform to control thepower transfer. As discussed in greater detail below, the control andcommunications system 26 also interfaces with other subsystems of thepower transmitter 20. For example, the control and communications system26 may interface with other elements of the power transmitter 20 foruser interface purposes.

Referring now to FIG. 3, with continued reference to FIGS. 1 and 2,subcomponents and/or systems of the control and communications system 26are illustrated. The control and communications system 26 may include atransmission controller 28, a communications system 29, a driver 48, anda memory 27.

The transmission controller 28 may be any electronic controller orcomputing system that includes, at least, a processor which performsoperations, executes control algorithms, stores data, retrieves data,gathers data, controls and/or provides communication with othercomponents and/or subsystems associated with the power transmitter 20,and/or performs any other computing or controlling task desired. Thetransmission controller 28 may be a single controller or may includemore than one controller disposed to control various functions and/orfeatures of the power transmitter 20. Functionality of the transmissioncontroller 28 may be implemented in hardware and/or software and mayrely on one or more data maps relating to the operation of the powertransmitter 20. To that end, the transmission controller 28 may beoperatively associated with the memory 27. The memory may include one ormore of internal memory, external memory, and/or remote memory (e.g., adatabase and/or server operatively connected to the transmissioncontroller 28 via a network, such as, but not limited to, the Internet).The internal memory and/or external memory may include, but are notlimited to including, one or more of a read only memory (ROM), includingprogrammable read-only memory (PROM), erasable programmable read-onlymemory (EPROM or sometimes but rarely labelled EROM), electricallyerasable programmable read-only memory (EEPROM), random access memory(RAM), including dynamic RAM (DRAM), static RAM (SRAM), synchronousdynamic RAM (SDRAM), single data rate synchronous dynamic RAM (SDRSDRAM), double data rate synchronous dynamic RAM (DDR SDRAM, DDR2, DDR3,DDR4), and graphics double data rate synchronous dynamic RAM (GDDRSDRAM, GDDR2, GDDR3, GDDR4, GDDR5, a flash memory, a portable memory,and the like. Such memory media are examples of nontransitory machinereadable and/or computer readable memory media.

While particular elements of the control and communications system 26are illustrated as independent components and/or circuits (e.g., thedriver 48, the memory 27, the communications system 29, among othercontemplated elements) of the control and communications system 26, suchcomponents may be integrated with the transmission controller 28. Insome examples, the transmission controller 28 may be an integratedcircuit configured to include functional elements of one or both of thetransmission controller 28 and the power transmitter 20, generally.

As illustrated, the transmission controller 28 is in operativeassociation, for the purposes of data transmission, receipt, and/orcommunication, with, at least, the memory 27, the communications system29, the power conditioning system 40, the driver 48, and the sensingsystem 50. The driver 48 may be implemented to control, at least inpart, the operation of the power conditioning system 40. In someexamples, the driver 48 may receive instructions from the transmissioncontroller 28 to generate and/or output a generated pulse widthmodulation (PWM) signal to the power conditioning system 40. In somesuch examples, the PWM signal may be configured to drive the powerconditioning system 40 to output electrical power as an alternatingcurrent signal, having an operating frequency defined by the PWM signal.

The sensing system 50 may include one or more sensors, wherein eachsensor may be operatively associated with one or more components of thepower transmitter 20 and configured to provide information and/or data.The term “sensor” is used in its broadest interpretation to define oneor more components operatively associated with the power transmitter 20that operate to sense functions, conditions, electrical characteristics,operations, and/or operating characteristics of one or more of the powertransmitter 20, the power receiver 30, the input power source 12, thebase station 11, the transmission coil 21, the receiver coil 31, alongwith any other components and/or subcomponents thereof.

As illustrated in the embodiment of FIG. 4, the sensing system 50 mayinclude, but is not limited to including, a thermal sensing system 52,an object sensing system 54, a receiver sensing system 56, electricalsensor(s) 57 and/or any other sensor(s) 58. Within these systems, theremay exist even more specific optional additional or alternative sensingsystems addressing particular sensing aspects required by anapplication, such as, but not limited to: a condition-based maintenancesensing system, a performance optimization sensing system, astate-of-charge sensing system, a temperature management sensing system,a component heating sensing system, an IoT sensing system, an energyand/or power management sensing system, an impact detection sensingsystem, an electrical status sensing system, a speed detection sensingsystem, a device health sensing system, among others. The object sensingsystem 54, may be a foreign object detection (FOD) system.

Each of the thermal sensing system 52, the object sensing system 54, thereceiver sensing system 56 and/or the other sensor(s) 58, including theoptional additional or alternative systems, are operatively and/orcommunicatively connected to the transmission controller 28. The thermalsensing system 52 is configured to monitor ambient and/or componenttemperatures within the power transmitter 20 or other elements nearbythe power transmitter 20. The thermal sensing system 52 may beconfigured to detect a temperature within the power transmitter 20 and,if the detected temperature exceeds a threshold temperature, thetransmission controller 28 prevents the power transmitter 20 fromoperating. Such a threshold temperature may be configured for safetyconsiderations, operational considerations, efficiency considerations,and/or any combinations thereof. In a non-limiting example, if, viainput from the thermal sensing system 52, the transmission controller 28determines that the temperature within the power transmitter 20 hasincreased from an acceptable operating temperature to an undesiredoperating temperature (e.g., in a non-limiting example, the internaltemperature increasing from about 20° Celsius (C) to about 50° C., thetransmission controller 28 prevents the operation of the powertransmitter 20 and/or reduces levels of power output from the powertransmitter 20. In some non-limiting examples, the thermal sensingsystem 52 may include one or more of a thermocouple, a thermistor, anegative temperature coefficient (NTC) resistor, a resistancetemperature detector (RTD), and/or any combinations thereof.

As depicted in FIG. 4, the transmission sensing system 50 may includethe object sensing system 54. The object sensing system 54 may beconfigured to detect presence of unwanted objects in contact with orproximate to the power transmitter 20. In some examples, the objectsensing system 54 is configured to detect the presence of an undesiredobject. In some such examples, if the transmission controller 28, viainformation provided by the object sensing system 54, detects thepresence of an undesired object, then the transmission controller 28prevents or otherwise modifies operation of the power transmitter 20. Insome examples, the object sensing system 54 utilizes an impedance changedetection scheme, in which the transmission controller 28 analyzes achange in electrical impedance observed by the transmission coil 21against a known, acceptable electrical impedance value or range ofelectrical impedance values. Additionally or alternatively, in someexamples the object sensing system 54 may determine if a foreign objectis present by measuring power output associated with the powertransmitter 20 and determining power input associated with a receiverassociated with the power transmitter 20. In such examples, the objectsensing system 54 may calculate a difference between the powerassociated with the power transmitter 20 and the power associated withthe receiver and determine if the difference indicates a loss,consistent with a foreign object not designated for wireless powertransmission.

Additionally or alternatively, the object sensing system 54 may utilizea quality factor (Q) change detection scheme, in which the transmissioncontroller 28 analyzes a change from a known quality factor value orrange of quality factor values of the object being detected, such as thereceiver coil 31. The “quality factor” or “Q” of an inductor can bedefined as (frequency (Hz)×inductance (H))/resistance (ohms), wherefrequency is the operational frequency of the circuit, inductance is theinductance output of the inductor and resistance is the combination ofthe radiative and reactive resistances that are internal to theinductor. “Quality factor,” as defined herein, is generally accepted asan index (figure of measure) that measures the efficiency of anapparatus like an antenna, a circuit, or a resonator. In some examples,the object sensing system 54 may include one or more of an opticalsensor, an electro-optical sensor, a Hall effect sensor, a proximitysensor, and/or any combinations thereof.

The receiver sensing system 56 is any sensor, circuit, and/orcombinations thereof configured to detect presence of any wirelessreceiving system that may be couplable with the power transmitter 20. Insome examples, if the presence of any such wireless receiving system isdetected, wireless transmission of electrical energy, electrical power,electromagnetic energy, and/or data by the power transmitter to saidwireless receiving system is enabled. In some examples, if the presenceof a wireless receiver system is not detected, wireless transmission ofelectrical energy, electrical power, electromagnetic energy, and/or datais prevented from occurring. Accordingly, the receiver sensing system 56may include one or more sensors and/or may be operatively associatedwith one or more sensors that are configured to analyze electricalcharacteristics within an environment of or proximate to the powertransmitter 20 and, based on the electrical characteristics, determinepresence of a power receiver 30.

The electrical sensor(s) 57 may include any sensors configured fordetecting and/or measuring any current, voltage, and/or power within thepower transmitter 20. Information provided by the electrical sensor(s)57, to the transmission controller 28, may be utilized independentlyand/or in conjunction with any information provided to the transmissioncontroller 28 by one or more of the thermal sensing system 52, theobject sensing system 54, the receiver sensing system 56, the othersensor(s) 58, and any combinations thereof.

Referring now to FIG. 5, and with continued reference to FIGS. 1-4, ablock diagram illustrating an embodiment of the power conditioningsystem 40 is illustrated. At the power conditioning system 40,electrical power is received, generally, as a DC power source, via theinput power source 12 itself or an intervening power converter,converting an AC source to a DC source (not shown). A voltage regulator46 receives the electrical power from the input power source 12 and isconfigured to provide electrical power for transmission by the coil 21and provide electrical power for powering components of the powertransmitter 20. Accordingly, the voltage regulator 46 is configured toconvert the received electrical power into at least two electrical powersignals, each at a proper voltage for operation of the respectivedownstream components: a first electrical power signal to electricallypower any components of the power transmitter 20 and a second portionconditioned and modified for wireless transmission to the wirelessreceiver system 30. As illustrated in FIG. 3, such a first portion istransmitted to, at least, the sensing system 50, the transmissioncontroller 28, and the communications system 29; however, the firstportion is not limited to transmission to just these components and canbe transmitted to any electrical components of the power transmitter 20.

The second portion of the electrical power is provided to an amplifier42 of the power conditioning system 40, which is configured to conditionthe electrical power for wireless transmission by the coil 21. Theamplifier may function as an inverter, which receives an input DC powersignal from the voltage regulator 46 and generates an AC as output,based, at least in part, on PWM input from the transmission controlsystem 26. The amplifier 42 may be or include, for example, a powerstage inverter. The use of the amplifier 42 within the powerconditioning system 40 and, in turn, the power transmitter 20 enableswireless transmission of electrical signals having much greateramplitudes than if transmitted without such an amplifier. For example,the addition of the amplifier 42 may enable the wireless transmissionsystem 20 to transmit electrical energy as an electrical power signalhaving electrical power from about 10 milliwatts (mW) to about 60 W.

FIG. 6 is an exemplary schematic diagram 120 for an embodiment of thepower transmitter 20. In the schematic, the amplifier 42 is afull-bridge inverter 142 which drives the transmitter coil 21 and aseries capacitor Cs. In some examples, wherein the operating frequencyof the power transmitter 20 is in the range of about 87 kHz and about205 kHz, the transmitter coil 21 has a self-inductance in a range ofabout 5 μH to about 7 μH. In some such examples, Cs has a capacitance ina range of about 400 nF to about 450 nF.

Based on controls configured by the control and communications system26, an input power source 112, embodying the input power source 12, isaltered to control the amount of power transferred to the power receiver30. The input voltage of the input power source 112 to the full-bridgeinverter 142 may be altered within a range of about 1 volt (V) to about19 V, to control power output. In such examples, the resolution of thevoltage of the input power source 112 may be 10 millivolts (mV) or less.In some examples, when the power transmitter 20, 120 first applies apower signal for transfer to the power receiver 30, the power signal ofthe input power source 112 has an initial input power voltage in a rangeof about 4.5 V to about 5.5 V.

The transmitter coil 21 may be of a wire-wound type, wound of, forexample, Litz wire. As defined herein, Litz wire refers to a type ofmultistrand wire or cable utilized in electronics to carry analternating current at a frequency. Litz wire is designed to reduce skineffect and proximity effect losses in conductors at frequencies up toabout 1 MHz and consists of many thin wire strands, individuallyinsulated and twisted or woven together, following a pattern. In someexamples, the Litz wire may be no. 17 American Wire Gauge (AWG) (1.15mm) type 2 Litz wire, having 105 strands of no. 40 AWG (0.08 mmdiameter), or equivalent wire. In some examples, the Litz wire used forthe transmitter coil 21 may be a bifilar Litz wire. To that end,utilizing thicker Litz wire, such as the no. 17 AWG type 2 Litz wire,utilizing bifilar Litz wire, and combinations thereof, may result in anincreased Quality Factor (Q) for the transmitter coil 21 and higher Qmay be directly related to increases in gap 17 height and/or Z-Distance.As Q is directly related to the magnitude of the magnetic field producedby the transmitter antenna 21 and, thus, with a greater magnitudemagnetic field produced, the field emanating from the transmissionantenna 21 can reach greater Z-distances and/or charge volumes, incomparison to legacy transmission coils, having lower Q designs. WhileLitz wire is described and illustrated, other equivalents and/orfunctionally similar wires may be used. Furthermore, other sizes andthicknesses of Litz wire may be used.

Turning to FIG. 7, an exemplary diagram 121, for portraying dimensionsof the transmitter antenna 21, is illustrated. The diagram 121 is a topperspective view of the transmitter antenna 21 and shows a top face 60of the transmitter antenna 21. Note that the diagram 121 is notnecessarily to scale and is for illustrative purposes. The top face 60and the transmitter antenna 21, generally, are relatively circular inshape. As illustrated, an outer diameter d_(o) is defined as an exteriordiameter of the transmitter antenna 21. In some examples, the outerdiameter d_(o) has an outer diameter length in a range of about 40 mm toabout 50 mm. An inner diameter d_(i) is defined as the diameter of thevoid space in the interior of the transmitter antenna 21. The innerdiameter d_(i) may have an inner diameter length in a range of about 15mm to about 25 mm. The outer diameter d_(o) and the inner diameter d_(i)may be relatively concentric, with respect to one another. Thetransmitter coil 21 has a thickness t_(w), which is defined as thethickness of the wire of the coil. The thickness t_(w) may be in a rangeof about 2 mm to about 3 mm. In such examples, the transmitter coil 21may be made of Litz wire and include at least two layers, the at leasttwo layers stacked upon each other. Utilization of one or more of anincreased inner diameter an increased outer diameter d_(o), multipleLitz wire layers for the antenna 21, specific dimensions disclosedherein, and/or combinations thereof, may be beneficial in achievinggreater gap 17 heights and/or Z-distances. Other shapes and sizes of thetransmitter antenna 21 may be selected based on the configuration withthe selection of the shape and size of the shielding of the transmittercoil. In the event that a desired shielding in required, the transmitterantenna 21 may be shaped and sized such that the shielding surrounds thetransmitter antenna 21 in accordance with an embodiment.

Turning now to FIG. 8, a cross-sectional view of the transmitter coil21, within the base station 11 and partially surrounded by a shielding80 of the transmitter coil 21, is illustrated. The shielding 80comprises a ferrite core and defines a cavity 82, the cavity configuredsuch that the ferrite core substantially surrounds all but the top face60 of the transmitter antenna 21 when the transmitter antenna 21 isplaced in the cavity. As used herein, “surrounds” is intended to includecovers, encircles, enclose, extend around, or otherwise provide ashielding for. “Substantially surrounds,” in this context, may take intoaccount small sections of the coil that are not covered. For example,power lines may connect the transmitter coil 21 to a power source. Thepower lines may come in via an opening in the side wall of the shielding80. The transmitter coil 21 at or near this connection may not becovered. In another example, the transmitter coil 21 may rise slightlyout of the cavity and thus the top section of the side walls may not becovered. By way of example, substantially surrounds would includecoverage of at least 50+% of that section of the transmitter antenna.However, in other examples, the shielding may provide a greater orlesser extent of coverage for one or more sides of the transmitterantenna 21.

In an embodiment, as shown in FIG. 8, the shielding 80 surrounds atleast the entire bottom section of the transmitter antenna 21 and almostall of the side sections of the transmitter antenna 21. As used herein,the entire bottom section of the transmitter antenna 21 may include, forexample, the entire surface area of the transmitter antenna 21 or all ofthe turns of the Litz wire of the transmitter antenna 21. With respectto the side walls, as shown in FIG. 8, the magnetic ring 84 does notextend all the way up the side wall of the transmitter antenna 21.However, as shown in other illustrations, the side wall may extend allthe way up the side wall.

In another embodiment, the shielding 80 may surround less than theentire bottom section of the transmitter antenna 21. For example,connecting wires (e.g., connecting wires 292, as best illustrated inFIGS. 10A, 10B and discussed below) may be run through an opening in thebottom of the shielding 80.

In an embodiment, as shown in FIG. 8, the shielding 80 is an “E-Core”type shielding, wherein the cavity 82 and structural elements of theshielding 80 are configured in an E-shape configuration, when theshielding is viewed, cross-sectionally, in a side view. The E-Coreconfiguration is further illustrated in FIG. 9, which is a perspectiveview of the shielding 80. The shielding 80 may include a magnetic core86, a magnetic backing 85, and a magnetic ring 84. The magnetic core 86is spaced inwardly from the outer edge of the magnetic backing 85 andprojects in an upward direction from the top surface of the magneticbacking 85. The magnetic core 86 and the magnetic ring 84 function tosurround the transmitter coil 21 and to direct and focus magneticfields, hence improving coupling with the receiver coil 31 of the powerreceiver 30.

In addition to covering the entire outer diameter of the transmittercoil 21, the shielding 80 may also cover the inner diameter d_(i) of thetransmitter coil 21. That is, as shown, the inner section of the E-Coreconfiguration may protrude upward through the middle of the transmittercoil 21.

In an embodiment, the cavity 82 is configured such that the shielding 80covers the entire bottom section of the transmitter coil 21 and theentire side sections of the transmitter coil 21. The top section of thetransmitter coil 21 is not covered. The bottom section of thetransmitter coil 21 is the side of the transmitter coil 21 that isopposite of the direction of the primary power transfer to the receivercoil 31. With a wire wound transmitter coil 21, the side section of thetransmitter coil 21 includes the side section of the outer most windingof the coil 21.

FIG. 10A is a perspective view of the transmitter coil 21 and theembodiment of the E-core shielding of FIG. 9 and FIG. 10B is an explodedperspective view of the transmitter coil 21 and the embodiment of theE-core shielding of FIG. 9. The transmitter coil 21 is positioned abovethe shielding 80, whose combination of structural bodies, as discussedabove, may include the combination of the magnetic core 86, the magneticbacking 85, and magnetic ring 84. This magnetic shielding combinationfunctions to help direct and concentrate magnetic fields created bytransmitter coil 21 and can also limit side effects that would otherwisebe caused by magnetic flux passing through nearby metal objects. In someexamples, the magnetic ring defines an opening 88, in which a connectingwire 292 of the transmitter coil 21 can exit the shielding 80.

As defined herein, a “shielding material,” from which the shielding 80is formed, is a material that captures a magnetic field. An example ofwhich is a ferrite material. The ferrite shield material selected forthe shielding 80 also depends on the operating frequency, as the complexmagnetic permeability (μ=μ′−j*μ″) is frequency dependent. The materialmay be a sintered flexible ferrite sheet or a rigid shield and becomposed of varying material compositions. In some examples, the ferritematerial for the shielding 80 may include a Ni—Zn ferrite, a Mn—Znferrite, and any combinations thereof.

Returning now to FIG. 8 and with continued reference to FIGS. 9 and 10,the shielding 80 is aligned with the transmitter antenna 21 such thatthe shielding 80 substantially surrounds the transmitter antenna 21 onall sides, aside from the top face 60. In other words, the transmitterantenna 21 may be wound around the magnetic core 86 and be surrounded,on the bottom and sides, respectively, by the magnetic backing 85 andthe magnetic ring 84. As illustrated, the shielding 80, in the form ofone or both of the magnetic backing and the magnetic core, may extendbeyond the outer diameter d_(o) of the transmitter antenna 21 by ashielding extending distance d_(e). In some examples, the shieldingextending distance d_(e) may be in a range of about 5 mm to about 6 mm.The shielding 80, at the magnetic backing 85, and the transmitter coil21 are separated from one another by a separation distance d_(s), asillustrated. In some examples, the separation distance d_(s) may be in arange of about 0.1 mm and 0.5 mm.

An interface surface 70 of the base station 11 is located at aninterface gap distance d_(int) from the transmitter coil 21 and theshielding 80. The interface surface 70 is a surface on the base station11 that is configured such that when a power receiver 30 is proximate tothe interface surface 70, the power receiver 30 is capable of couplingwith the power transmitter 20, via near-field magnetic induction betweenthe transmitter antenna 21 and the receiver antenna 31, for the purposesof wireless power transfer. In some examples, the interface gap distanced_(int) maybe in a range of about 8 mm to about 10 mm. In such examples,the d_(int) is greater than the standard required Z-distance for Qi™certified wireless power transmission (3-5 mm). Accordingly, by having agreater d_(int), empty space and/or an insulator can be positionedbetween the transmission coil 21 and the interface surface 70 tomitigate heat transfer to the interface surface 70, the power receiver30, and/or the electronic device 14 during operation. Further, such agreater d_(int) allows for interface design structures in which objectson or attached to the electronic device 14 may remain attached to theelectronic device during operation. As described in greater detailbelow, design features of the interface surface 70 may be included forinteraction with such objects for aligning the power transmitter 20 andthe power receiver 30 for operation.

Returning now to FIG. 10B, an exemplary coil 221 for use as thetransmitter antenna 21 is illustrated in the exploded view of thetransmitter antenna 21 and shielding 80. The coil 221 includes one ormore bifilar Litz wires 290 for the first bifilar coil layer 261 and thesecond bifilar coil layer 262. “Bifilar,” as defined herein, refers to awire having two closely spaced, parallel threads and/or wires. Each ofthe first and second bifilar coil layers 261, 262 include N number ofturns. In some examples, each of the first and second bifilar coillayers 261, 262 include about 4.5 turns and/or the bifilar coil layers261, 262 may include a number of turns in a range of about 4 to about 5.In some examples, the one or more bifilar Litz wire 290 may be no. 17AWG (1.15 mm) type 2 Litz wire, having 105 strands of no. 40 AWG (0.08mm diameter), or equivalent wire. Utilization of multiple layers, thickLitz wire, bifilar Litz wire, and any combinations thereof, may resultin the coil 21 achieving greater Q and/or may result in increases in gap17 height and/or Z-distance between the coil 21 and a receiver coil.

FIGS. 11A-E illustrate a surface mountable power transmitter 420, whichmay include similar and/or equivalent elements to the power transmitter20 including, but not limited to the transmitter antenna 21, the controland communications unit 26, the power conditioning system 40, thesensing system 50, any components of the aforementioned elements, or anycombinations thereof. In addition to the cited elements of the powertransmitter 20, the surface mountable power transmitter 420 furtherincludes a surface mountable housing 400. The surface mountable housing400 is substantially connected to, at least, the transmitter antenna 21.

The surface mountable housing 400 is configured for use to mount, atleast, the transmitter antenna 21 to an underside of a structuralsurface, such that the transmitter antenna 21 is configured to couplewith a receiver antenna 31 of the power receiver 30 when the receiverantenna is proximate to a top side of the structural surface. Suchconfigurations of the housing 400 and a structural surface 500 will bediscussed in more detail, with respect to FIGS. 12-14. A “structuralsurface,” as defined herein, is any surface made out of a dielectricmaterial wherein a user of the electronic device 14 would desire toprovide wireless power transfer to the electronic device 14, and saidsurface is within an environment where wireless power transfer can occur(e.g., an environment wherein electricity is available to provide to thepower transmitter 420). Examples of structural surfaces include, but arenot limited to including, a desk, a desk top, a counter, a counter top,a bar, a table, a table top, an end table, an end table top, furniture,outdoor furniture, a chair, a chair arm, an arm rest, a surface oflounge furniture, a surface of interior seating furniture, home theaterfurniture, stands, a work space surface, a conference room tablesurface, a wall, a protrusion from a wall, a public surface, a surfaceof a vehicle, a bar, a bar top, a ledge, a shelf, a book shelf, anentertainment center, a cabinet surface, among other contemplatedsurfaces and/or portions of surfaces. Such a surface could be made outof, for example, a wood, polymer, concrete, laminated composite,leather, glass, ceramic, foam, among other dielectric materials used forthe surface.

The surface mountable housing 400 may include a heat sink 430, which isconfigured to rest, at least in part, below the transmitter antenna (asbest illustrated in the exploded view of the housing 400 in FIG. 11C),when the power transmitter 420 is connected to the structural surface500. The heat sink 430 is configured to direct heat generated by thepower transmitter 420 away from, at least, the structural surface 500.In some examples and as best illustrated in FIGS. 11B and 11E, the heatsink 430 may include one or more cut outs, 422, the one or more cutoutsconfigured to increase an external surface area of the heat sink, thusallowing heat to spread over the increased surface area, directingand/or dissipating heat away from the power transmitter 20 componentsand/or the associated surface. Inclusion of the cutouts 422 results inhigher rates of heat dissipation into the environment and, as a result,lower temperatures on the heat sink surfaces and inside the module.

Additionally or alternatively, in some examples, the heat sink 430 maybe CNC machined or formed using a die casting, forging, stamping oranother manufacturing process suitable for low cost mass production. Insome examples, the heat sink 430 may be formed of a metal that has arelatively high thermal conductivity. The heat sink 420, at least inpart, can be made out of any metal or metal alloy suitable for diecasting and having a high thermal conductivity, such as, but not limitedto, an aluminum or an aluminum alloy. In some examples, wherein the heatsink 430 is formed by die casting, one or more surfaces of the heat sink430 are formed with drafts on an exterior surface of the heat sink 430.

In order to increase emissivity, the heat sink can be finished withdifferent coatings, chemically treated, and/or painted. Increasedemissivity increases heat dissipated by the heat sink, reducingtemperature rise of the components inside the module 400. In someexamples, an aluminum, die-casted heat sink 430 is anodized to produce auniform black finish, which increases emissivity and, thus, improvesheat dissipation by the heat sink 430.

Further, in some examples, the power transmitter 420 includes atransmitter electronics circuit board 435. The circuit board 435 may beany circuit board, upon which components of one or more of the controland communications system 26, the power conditioning system 40, and/orthe sensing system 50, among other things, may be connected, mounted,operable with, and/or otherwise operatively associated with the circuitboard 430. In such examples, the heat sink 430 is configured to conductand dissipate heat, generated by one or more of the electronics circuitboard 435 and/or any components located on the electronic circuit board435, away from the structural surface 500. In some examples, the circuitboard 435 may be operatively associated with an external power connector411, which may be configured to interface with the input power source 11to provide input power to the power transmitter 420. The external powerconnector 411 may be any input and/or connector that provides anelectrical connection to the input power source, such as, but notlimited to, a barrel connector, a Universal Serial Bus (USB) connector,a USB-C connector, a mini-USB connector, Lightning connector, aThunderbolt connector, a proprietary electrical connector, an AC adaptorconnector, among other contemplated connectors.

In some examples, a thermal interface material (TIM) 432 is disposedbetween the electronics circuit board 435 and the heat sink 430. In someexamples, the TIM 432 is placed proximate to one or more heat producingcomponents on and/or operatively associated with the electronics circuitboard 435 and/or the power transmitter 420. The thermal interfacematerial 432 is configured to displace air and provide a low thermalimpedance path between the electronics circuit board 435 components andthe heat sink 430. Examples of thermal interface materials include, butare not limited to including a thermal paste, a thermal adhesive, athermal gap filter, a thermally conductive pad, a thermal tape, aphase-change material, a metal thermal interface, or combinationsthereof. In some examples, materials used in the thermal interfacematerials may include, but are not limited to including materials suchas, but not limited to, epoxies, silicones, urethanes, and acrylates,solvent-based systems, hot-melt adhesives, and pressure-sensitiveadhesive tapes, Aluminum oxide, boron nitride, zinc oxide, aluminumnitride, Galinstan, gallium, epoxy resins, cyanoacrylate, metal oxides,silica, ceramic microspheres, paraffin wax, copper, among othermaterials used in thermal interface materials.

In some examples, the housing 400 further includes an antenna housing410, the antenna housing substantially surrounding a side wall (e.g.,the magnetic ring 84 of the shielding 80 of the antenna 21) of theantenna 21. The antenna housing 410 is connected to the heat sink 420,via, for example, a connection system 455 of the housing 400, asdiscussed below. The antenna housing 410 may be utilized to fix theantenna location within the module, prevent any foreign objects made outof metal to come in vicinity of the antenna, once the module isinstalled, hold together components of the housing 400 and/or for thepurposes of packaging and/or obscuring components of the powertransmitter 420 in a finished product of the power transmitter 420. Insome examples, portions of the antenna housing 410 may define a portionof the connection system 455, as is discussed in more detail below. Insome examples, the antenna housing 410 is formed of an injectionmoldable polymer and/or any other substantially dielectric materials.

Turning now to FIG. 12 and with continued reference to FIGS. 1-11, thepower transmitter 420 is illustrated in relation to a first structuralsurface 500A, to which the power transmitter 420 may be attached andfunction to transmit wireless power to the power receiver 30 of theelectronic device, via coupling between the transmitter antenna 21 andthe receiver antenna 31 of the power receiver 30. The structural surface500A has a top side 504A and an underside 502A; as discussed above, thepower transmitter 420 is configured to be mounted to the underside 502A.As best illustrated in FIG. 12, the connection system 455 is included toconnect the power transmitter 400 to the underside 502 of the structuralsurface 500. As illustrated, the connection system 455 may include oneor more connection holes 452; the connection holes 452 configured toaccept one or more fasteners 454 which may mate with the connection hole452 and then enter the structural surface 500 to secure the powertransmitter 420 to the underside 502. While illustrated as a combinationof a holes 452 and fasteners 454, the connection system 455 is certainlynot limited to a hole/fastener combination and may be and/or include anadhesive, a removable connector, a connective material connection (e.g.Velcro), a magnetic connection, a sealant connection, a fusedconnection, among other systems, methods, and apparatus for connectingthe power transmitter 420 to the structural surface 500.

FIGS. 13A and 13B illustrate the power transmitter 400 mounted to asecond structural surface 500B, the structural surface 500B including ahole 510A. The hole defines a hole ceiling 514A and a hole opening 512A.A hole depth 515A is defined as a distance between the hole ceiling 514Aand the hole opening 512A. In some examples, the hole 510A is configuredto receive the power transmitter 420, when being mounted on undersidesurface 502A proximate to the hole ceiling 514A. In some examples, thehole thickness 515A is less than the surface thickness 505B and thehousing 400 is configured to mount to the hole ceiling 514A.

In another example, FIG. 14 illustrates a third structural surface 500C,having a top side 504C and an underside 502C, defining a surfacethickness 505C. The structural surface 500C defines a hole 510B, whichhas a hole ceiling 514B and a hole opening 512B. A thickness between thehole ceiling 514B and the hole opening 512B defines a hole thickness515B. In comparison to the hole 510A of FIG. 13, the hole 510B has asignificantly larger thickness 515B, such that the hole thickness 515Bis greater than a thickness of the power transmitter 420. In someexamples, the hole 510A is configured to receive the power transmitter420, when being mounted on underside surface 502C proximate to the holeceiling 514B. In some examples, the hole thickness 515B is less than thesurface thickness 505B and the housing 400 is configured to mount to thehole ceiling 514B. In some examples, the surface thickness 505C is in arange of about 20 mm to about 60 mm and the hole thickness 515B is in arange of about 5 mm to about 50 mm.

As illustrated in FIG. 14, the housing 400 is operatively associatedwith an alternative connection system 465, configured for connecting thehousing 400 to the underside of the surface 504C. The connection system465 includes a bracket 460 for mounting to the underside of the surface504, the bracket 460 defining one or more holes 462, within whichfasteners 454 may be inserted to connect the bracket 460 and, byassociation, the housing 400 to the underside of the surface 504C. Insome examples, the connection system 465 may include an external thermalconnector 466, which connects to the bracket 460 to the heat sink 430via, for example, a center hole 438 of the heat sink 430. The thermalconnector 466 may be comprised, at least in part, of an electricallyconductive material, similar to the heat sink 430, and be configured tofurther draw heat away and/or dissipate heat from the heat sink 430, thepower transmitter 20, and/or the surface 504.

FIG. 15 is an exemplary, actual, simulation 600 of a magnetic fieldgenerated by a transmitter coil 21 and/or its associated powertransmitter 20, 420 and captured by an exemplary receiver coil 31 and/orits associated power receiver 30, when the transmitter coil 21 and/orpower transmitter 20, 420 are designed, manufactured, and/or implementedaccording to the teachings of this disclosure. The receiver coil 31 wasas a standard Qi™ receiver coil utilized by commercial electronicdevices, such as mobile phones, and the receiver coil 31 was modelledwith a metal piece behind the coil, wherein the metal piece was used tosimulate a battery. The simulation shows that the magnetic fieldgenerated by the transmitter coil 21 was captured by the receiver coil31 at an extended Z-distance of 9 mm. As discussed previously, Qi™wireless transmitter coils typically operate between coil-to-coildistances of about 3 mm to about 5 mm. The shaped-magnetics of thetransmitter coil 21 have shown to favorably reshape a magnetic field sothat coil-to-coil coupling can occur at extended Z-distances, whereinthe Z-distances are extended about 2 times to about 5 times the distanceof standard Qi™ wireless power transmitters. Furthermore, theshaped-magnetics of the present application can extend coupling ofpresent day a Qi™ wireless power transmitter at a Z-distance rangingabout 5 mm to about 25 mm. Any of the E-core and/or additional oralternative custom shapes for the shielding 80, may successfully be usedto reshape the magnetic field for extended Z-distance coupling by aminimum of a 5% compared to standard present-day power transmitters. Inaddition, any of the E-core and custom shapes previously discussed, eachin conjunction with its relation to a coil to the magnetic has also mayfurther increase z-direction coupling by at least another 5%. Anembodiment comprising a structure, the structure comprising a coil and amagnetic material, wherein a gap between the coil and the magneticmaterial residing at the inner diameter of the coil comprises 2 mm,reshapes the magnetic field so that coupling increases by 5%.

Further, as increasing the separation gap 17 may be associated with arise in power levels, proper thermal mitigation via the systems andmethods disclosed herein allows for higher separation gap wireless powertransmitters. The systems and apparatus described herein allow for suchthermal mitigation, so that the large separation gap is achieved withoutdoing damage to one or more of the power transmitter, the device to bepowered and/or power receiver associated with said device, the surfaceto which the power transmitter is mounted, or combinations thereof.

Additionally, the utilization of the power transmitters and/ortransmitter antennas, disclosed herein, as part of a surface mountablepower transmitter 420, allow for greater modularity in transmitterplacement, relative to the surface upon which the power transmitter ismounted. Further, in some examples, the extended separation distanceachieved by the power transmitters, disclosed herein, may allow forusage of surface mountable power transmitters on thicker surfacethicknesses and/or thicker materials for the surfaces, when comparedwith legacy surface-associated power transmitters.

As is discussed above, the transmitter coils 21, power transmitters 20,420, and/or base stations 11, disclosed herein, may achieve greatadvancements in Z-distance and/or gap 17 height, when compared tolegacy, low-frequency (e.g., in a range of about 87 kHz to about 205kHz) transmission coils, power transmitters, and/or base stations. Tothat end, an extended Z-distance not only expands a linear distance,within which a receiver may be placed and properly coupled with atransmitter, but an extended Z-distance expands a three-dimensionalcharging and/or operational volume (“charge volume”), within which areceiver may receive wireless power signals from a transmitter. For thefollowing example, the discussion fixes lateral spatial freedom (X and Ydistances) for the receiver coil, positioned relative to the transmittercoil, as a control variable. Accordingly, for discussion purposes only,one assumes that the X and Y distances for the base stations 11, powertransmitters 20, and/or transmitter coils 21 are substantially similarto the X and Y distances for the legacy system(s). However, it iscertainly contemplated that the inventions disclosed herein may increaseone or both of the X-distance and Y-distance. Furthermore, while theinstant example uses the exemplary range of 8-10 mm for the Z-distanceof the base stations 11, power transmitters 20, and/or transmitter coils21, it is certainly contemplated and experimental results have shownthat the base stations 11, power transmitters 20, and/or transmittercoils 21 are certainly capable of achieving Z-distances having a greaterlength than about 10 mm, such as, but not limited to, up to 15 mm and/orup to 30 mm. Accordingly, the following table is merely exemplary andfor illustration that the expanded Z-distances, achieved by the basestations 11, power transmitters 20, and/or transmitter coils 21, havenoticeable, useful, and beneficial impact on a charge volume associatedwith one or more of the base stations 11, power transmitters 20, and/ortransmitter coils 21.

Spatial Freedom Comparison Charge Charge Z-dist Z-dist Vol. Vol. X-distY-dist (min) (max) (min) (max) Legacy 5 mm 5 mm  3 mm  5 mm  75 mm³ 125mm³ 11, 20, 21 5 mm 5 mm  8 mm 10 mm 200 mm³ 250 mm³ (8-10 mm. ver.) 11,20, 21 5 mm 5 mm 10 mm 15 mm 250 mm³ 375 mm³ (15 mm. ver.) 11, 20, 21 5mm 5 mm 15 mm 30 mm 375 mm³ 750 mm³ (30 mm. ver.)Thus, by utilizing the base stations 11, power transmitters 20, and/ortransmitter coils 21, the effective charge volume may increase by morethan 100 percent, when compared to legacy, low-frequency wireless powertransmitters. Accordingly, the base stations 11, power transmitters 20,and/or transmitter coils 21 may achieve large Z-distances, gap heights,and/or charge volumes that were not possible with legacy low frequency,but thought only possible in lower power, high frequency (e.g., aboveabout 2 Mhz) wireless power transfer systems.

FIG. 16 is an example block diagram for a method 1200 for designing thepower transmitter 420. The method includes designing the surface mounthousing 400, as illustrated in block 1205. The method 1200 includesdesigning and/or selecting the transmitter coil 21 for the powertransmitter 420, as illustrated in block 1210. The method 1200 includestuning the power transmitter 420, as illustrated in block 1220. Suchtuning may be utilized for, but not limited to being utilized for,impedance matching.

The method 1200 further includes designing the power conditioning system40 for the power transmitter 240, as illustrated in block 1230. Thepower conditioning system 40 may be designed with any of a plurality ofpower output characteristic considerations, such as, but not limited to,power transfer efficiency, maximizing a transmission gap (e.g., the gap17), increasing output voltage to a receiver, mitigating power lossesduring wireless power transfer, increasing power output withoutdegrading fidelity for data communications, optimizing power output formultiple coils receiving power from a common circuit and/or amplifier,among other contemplated power output characteristic considerations.Further, at block 1240, the method 1200 may determine and optimize aconnection, and any associated connection components, to configureand/or optimize a connection between the input power source 12 and thepower conditioning system 40 of block 1230. Such determining,configuring, and/or optimizing may include selecting and implementingprotection mechanisms and/or apparatus, selecting and/or implementingvoltage protection mechanisms, among other things.

The method 1200 further includes designing and/or programing the controland communications system 26 of the power transmitter 420, asillustrated in block 1250. Components of such designs include, but arenot limited to including, the sensing system 50, the driver 41, thetransmission controller 28, the memory 27, the communications system 29,the thermal sensing system 52, the object sensing system 54, thereceiver sensing system 56, the electrical sensor(s) 57, the othersensor(s) 58, in whole or in part and, optionally, including anycomponents thereof.

FIG. 17 is an example block diagram for a method 2200 for manufacturingthe power transmitter 420. The method forming and/or manufacturing thesurface mount housing 400, as illustrated in block 1205. The method 2200includes manufacturing and/or selecting the transmitter coil 21 for thepower transmitter 420, as illustrated in block 2210. The method 2200includes tuning the power transmitter 420, as illustrated in block 2220.Such tuning may be utilized for, but not limited to being utilized for,impedance matching.

The method 2200 further includes manufacturing the power conditioningsystem 40 for the power transmitter 420, as illustrated in block 2230.The power conditioning system 40 may be designed and/or manufacturedwith any of a plurality of power output characteristic considerations,such as, but not limited to, power transfer efficiency, maximizing atransmission gap (e.g., the gap 17), increasing output voltage to areceiver, mitigating power losses during wireless power transfer,increasing power output without degrading fidelity for datacommunications, optimizing power output for multiple coils receivingpower from a common circuit and/or amplifier, among other contemplatedpower output characteristic considerations. Further, at block 2240, themethod 2200 may include connecting and/or optimizing a connection, andany associated connection components, to configure and/or optimize aconnection between the input power source 12 and the power conditioningsystem 40 of block 2230. Such determining, manufacturing, configuring,and/or optimizing may include selecting and implementing protectionmechanisms and/or apparatus, selecting and/or implementing voltageprotection mechanisms, among other things.

The method 2200 further includes designing and/or programing the controland communications system 26 of the power transmitter 420, asillustrated in block 2250. Components of such designs include, but arenot limited to including, the sensing system 50, the driver 41, thetransmission controller 28, the memory 27, the communications system 29,the thermal sensing system 52, the object sensing system 54, thereceiver sensing system 56, the electrical sensor(s) 57, the othersensor(s) 58, in whole or in part and, optionally, including anycomponents thereof.

As used herein, the phrase “at least one of” preceding a series ofitems, with the term “and” or “or” to separate any of the items,modifies the list as a whole, rather than each member of the list (i.e.,each item). The phrase “at least one of” does not require selection ofat least one of each item listed; rather, the phrase allows a meaningthat includes at least one of any one of the items, and/or at least oneof any combination of the items, and/or at least one of each of theitems. By way of example, the phrases “at least one of A, B, and C” or“at least one of A, B, or C” each refer to only A, only B, or only C;any combination of A, B, and C; and/or at least one of each of A, B, andC.

The predicate words “configured to”, “operable to”, and “programmed to”do not imply any particular tangible or intangible modification of asubject, but, rather, are intended to be used interchangeably. In one ormore embodiments, a processor configured to monitor and control anoperation or a component may also mean the processor being programmed tomonitor and control the operation or the processor being operable tomonitor and control the operation. Likewise, a processor configured toexecute code can be construed as a processor programmed to execute codeor operable to execute code.

A phrase such as “an aspect” does not imply that such aspect isessential to the subject technology or that such aspect applies to allconfigurations of the subject technology. A disclosure relating to anaspect may apply to all configurations, or one or more configurations.An aspect may provide one or more examples of the disclosure. A phrasesuch as an “aspect” may refer to one or more aspects and vice versa. Aphrase such as an “embodiment” does not imply that such embodiment isessential to the subject technology or that such embodiment applies toall configurations of the subject technology. A disclosure relating toan embodiment may apply to all embodiments, or one or more embodiments.An embodiment may provide one or more examples of the disclosure. Aphrase such an “embodiment” may refer to one or more embodiments andvice versa. A phrase such as a “configuration” does not imply that suchconfiguration is essential to the subject technology or that suchconfiguration applies to all configurations of the subject technology. Adisclosure relating to a configuration may apply to all configurations,or one or more configurations. A configuration may provide one or moreexamples of the disclosure. A phrase such as a “configuration” may referto one or more configurations and vice versa.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any embodiment described herein as“exemplary” or as an “example” is not necessarily to be construed aspreferred or advantageous over other embodiments. Furthermore, to theextent that the term “include,” “have,” or the like is used in thedescription or the claims, such term is intended to be inclusive in amanner similar to the term “comprise” as “comprise” is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “include,” “have,” or the like is used in the descriptionor the claims, such term is intended to be inclusive in a manner similarto the term “comprise” as “comprise” is interpreted when employed as atransitional word in a claim.

All structural and functional equivalents to the elements of the variousaspects described throughout this disclosure that are known or latercome to be known to those of ordinary skill in the art are expresslyincorporated herein by reference and are intended to be encompassed bythe claims. Moreover, nothing disclosed herein is intended to bededicated to the public regardless of whether such disclosure isexplicitly recited in the claims. No claim element is to be construedunder the provisions of 35 U.S.C. § 112, sixth paragraph, unless theelement is expressly recited using the phrase “means for” or, in thecase of a method claim, the element is recited using the phrase “stepfor.”

Reference to an element in the singular is not intended to mean “one andonly one” unless specifically so stated, but rather “one or more.”Unless specifically stated otherwise, the term “some” refers to one ormore. Pronouns in the masculine (e.g., his) include the feminine andneuter gender (e.g., her and its) and vice versa. Headings andsubheadings, if any, are used for convenience only and do not limit thesubject disclosure.

While this specification contains many specifics, these should not beconstrued as limitations on the scope of what may be claimed, but ratheras descriptions of particular implementations of the subject matter.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment. Conversely, various features that are described inthe context of a single embodiment can also be implemented in multipleembodiments separately or in any suitable sub-combination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to a subcombination or variation of a sub combination.

What is claimed is:
 1. A power transmitter for wireless power transferat an operating frequency selected from a range of about 87 kilohertz(kHz) to about 205 kHz, the power transmitter comprising: a control andcommunications unit; an inverter circuit configured to receive inputpower and convert the input power to a power signal; a transmitterantenna, the transmitter antenna including: a coil structure configuredto transmit the power signal to a device having a power receiver, thecoil structure comprising at least one layer of Litz wire, wherein thecoil structure has a top surface, a bottom surface, and a side surface;and a ferrite shielding structure comprising a magnetic core having anouter face, a magnetic backing having a top face, and a magnetic ringhaving an inner face, and the ferrite shielding structure having acavity defined by the outer face of the magnetic core, the top face ofthe magnetic backing, and the inner face of the magnetic ring, thecavity configured such that the ferrite shielding structuresubstantially surrounds at least a portion of the bottom surface of thecoil structure and at least a portion of the side surface of the coilstructure, and wherein the bottom surface of the coil structure and thetop face of the magnetic backing are separated by a separation distance;and a surface mountable housing, the surface mountable housing connectedto, at least, the transmitter antenna, and the surface mountable housingincluding a connector system configured for use to mount, at least, thetransmitter antenna to an underside of a structural surface such thatthe transmitter antenna is configured to couple with a receiver antennaof the power receiver when the receiver antenna is proximate to a topside of the structural surface, wherein, when the transmitter antenna ismounted to the underside of the structural surface, the top surface ofthe coil structure has a first height and the top side of the structuralsurface has a second height, wherein the second height is greater thanthe first height by a gap distance in a range of about 8 millimeters(mm) to about 15 mm.
 2. The power transmitter of claim 1, wherein atleast part of the surface mountable housing further includes a heatsink, the heat sink configured to rest, at least in part, below thetransmitter antenna, when the power transmitter is mounted to thestructural surface, and configured to direct heat generated by the powertransmitter away from the structural surface.
 3. The power transmitterof claim 2, further comprising a transmitter electronics circuit board,the transmitter electronics circuit board including components of one ormore of the control and communications circuit, the inverter circuit, ora combination thereof, and wherein the heat sink is further configuredto dissipate heat, generated by one or more of the transmitterelectronics circuit board or components located on the transmitterelectronics circuit board, away from the structural surface.
 4. Thepower transmitter of claim 3, further comprising a thermal interfacematerial, the thermal interface material disposed between thetransmitter electronics circuit board and the heat sink and configuredto direct heat from the transmitter electronics circuit board to theheat sink.
 5. The power transmitter of claim 4, wherein the thermalinterface material includes one or more of a thermal paste, a thermaladhesive, a thermal gap filter, a thermally conductive pad, a thermaltape, a phase-change material, a metal thermal interface, orcombinations thereof.
 6. The power transmitter of claim 2, wherein thesurface mountable housing further includes an antenna housing, theantenna housing substantially surrounding a side wall of the transmitterantenna, and wherein the antenna housing is connected to the heat sinkand positioned between the heat sink and the structural surface.
 7. Thepower transmitter of claim 2, wherein the heat sink defines one or morecut outs, each of the one or more cut outs configured to increaseexternal surface area of the heat sink.
 8. The power transmitter ofclaim 2, wherein the heat sink is formed, at least in part, fromaluminum.
 9. The power transmitter of claim 1, wherein the transmitterantenna is capable of transmitting the power signal to the powerreceiver via magnetic coupling with a receiver coil when the powerreceiver is positioned proximate to the top side of the structuralsurface and the receiver coil is separated from the coil structure ofthe transmitter antenna by the gap distance.
 10. The power transmitterof claim 1, wherein a surface thickness is defined as a thicknessbetween the underside of the structural surface and the top side of thestructural surface, and wherein the structural surface includes a hole,the hole defining a hole ceiling and a hole opening, wherein a holethickness is defined as a thickness between the hole ceiling and thehole opening, wherein the hole thickness is less than the surfacethickness, and wherein the surface mountable housing is configured tomount to the hole ceiling of the hole of the structural surface.
 11. Thepower transmitter of claim 10, wherein the surface thickness is in arange of about 20 mm to about 60 mm, and wherein the hole thickness isin a range of about 5 mm to about 50 mm.
 12. The power transmitter ofclaim 1, wherein the separation distance increases the magnetic couplingbetween the coil structure of the transmitter antenna and a receivercoil of the power receiver at an extended z-distance.
 13. The powertransmitter of claim 1, wherein the separation distance is in a range ofabout 0.1 millimeters (mm) to about 0.5 mm.
 14. A power transmitter forwireless power transfer at an operating frequency selected from a rangeof about 87 kilohertz (kHz) to about 205 kHz, the power transmittercomprising: a control and communications unit; an inverter circuitconfigured to receive input power and convert the input power to a powersignal; a transmitter antenna, the transmitter antenna including: a coilstructure configured to transmit the power signal to a device having apower receiver, the coil structure comprising at least one layer of Litzwire, wherein the coil structure has a top surface, a bottom surface,and a side surface; and a ferrite shielding structure comprising amagnetic core having an outer face, a magnetic backing having a topface, and a magnetic ring having an inner face, and the ferriteshielding structure having a cavity defined by the outer face of themagnetic core, the top face of the magnetic backing, and the inner faceof the magnetic ring, the cavity configured such that the ferriteshielding structure substantially surrounds at least a portion of thebottom surface of the coil structure and at least a portion of the sidesurface of the coil structure, and wherein the bottom surface of thecoil structure and the top face of the magnetic backing are separated bya separation distance; and a surface mountable housing, the surfacemountable housing connected to, at least, the transmitter antenna, andthe surface mountable housing including a connector system configuredfor use to mount, at least, the transmitter antenna to an underside of astructural surface such that the transmitter antenna is configured tocouple with a receiver antenna of the power receiver when the receiverantenna is proximate to a top side of the structural surface, wherein,when the transmitter antenna is mounted to the underside of thestructural surface, the top surface of the coil structure has a firstheight and the top side of the structural surface has a second height,wherein the second height is greater than the first height by a gapdistance in a range of about 8 millimeters (mm) to about 15 mm.
 15. Thesurface mountable power transmitter of claim 14, wherein the ferriteshielding structure is an E-Core type shielding structure and the cavityis configured in an E-shape configuration.
 16. The surface mountablepower transmitter of claim 14, wherein the at least one layer of Litzwire comprises a first layer and a second layer, and wherein the firstlayer includes a first number of turns in a range of about 4 turns toabout 5 turns, and wherein the second layer includes a second number ofturns in a range of about 4 turns to about 5 turns.
 17. The surfacemountable power transmitter of claim 16, wherein the first layer and thesecond layer comprise bifilar Litz wire.
 18. The surface mountable powertransmitter of claim 14, wherein the separation distance increases themagnetic coupling between the coil structure of the transmitter antennaand a receiver coil of the power receiver at an extended z-distance. 19.The surface mountable power transmitter of claim 14, wherein theseparation distance is in a range of about 0.1 millimeters (mm) to about0.5 mm.
 20. A surface mountable housing for a power transmitter forwireless power transfer at an operating frequency selected from a rangeof about 87 kilohertz (kHz) to about 205 kHz, the power transmitterincluding, at least, a transmitter antenna comprising a coil having aside surface and a bottom surface substantially surrounded by a ferritecore, the surface mountable housing comprising: a connector systemconfigured for use to mount, at least, the transmitter antenna to anunderside of a structural surface, such that the transmitter antenna isconfigured to couple with a receiver antenna of a power receiver whenthe receiver antenna is proximate to a top side of the structuralsurface; a heat sink comprising an outer side wall and a bottom walldefining a recess, the heat sink configured to rest, at least in part,below the transmitter antenna, when the power transmitter is mounted tothe structural surface, and configured to direct heat generated by thepower transmitter away from the structural surface; and an antennahousing comprising an outer face, a top face, an inner face, and abottom face, the antenna housing positioned within the recess of theheat sink such that the outer side wall of the heat sink substantiallysurrounds the outer face of the antenna housing, wherein the inner faceof the antenna housing substantially surrounds a side wall of theferrite core of the transmitter antenna, the antenna housing connectedto the heat sink and positioned between the heat sink and the structuralsurface, wherein, when the transmitter antenna is mounted to theunderside of the structural surface, a top surface of the transmitterantenna has a first height and the top side of the structural surfacehas a second height, wherein the second height is greater than the firstheight by a gap distance in a range of 8 millimeters (mm) to 15 mm; anda transmitter electronic circuit board that is positioned within therecess of the heat sink below the bottom face of the antenna housing andbelow a bottom wall of the ferrite core of the transmitter antenna andabove the bottom wall of the heat sink, wherein the connector systemconnects the heat sink to the antenna housing through at least a portionof the transmitter electronic circuit board when the surface mountablehousing is mounted to the underside of the structural surface.